1. 10/2007 M.Taborelli, TS-MME Structure Manufacturing, Achievements and Challenges M.Taborelli -Technology -Shape accuracy -Surface quality -Assembly accuracy Contributions of : G.Arnau-Izquierdo, A.Cherif, D.Glaude, R.Leuxe, J.Huopana, S.Mathot, CLIC study team

2. 10/2007 M.Taborelli, TS-MME Copper, disc structures - Machining by diamond turning: shape accuracy of 2-3m in the iris region -alignment of the discs on V-shaped marble before assembly in a stack: use external disc surface as reference. -assembly by vacuum brazing (T up to 820C) or by bolting - no rf-damping by design disc structures

3. 10/2007 M.Taborelli, TS-MME Ra = 0.05 m disc structures 30 GHz copper structures: surface quality Recrystallization after thermal treatment (vacuum brazing cycle at 820 C)

4. 10/2007 M.Taborelli, TS-MME Achieved accuracy for brazing assembly of disc structures: better than 5 µm Bookshelfing: assembly on aslope V-bench gives “tilted” discs Smaller and random error: assembly on vertical V-bench, as a tower 5 μm The type of error depends on the assembly procedure disc structures

5. 10/2007 M.Taborelli, TS-MME Copper quadrant structures: example 30GHz -machining by 3D milling: carbide tools or single crystal diamond tools -alignment of the quadrants still under study -assembly by bolting -rf-damping implemented in the design -target accuracy: 1 μm on shape!!! quadrant structures 160 mm 53 mm

6. 10/2007 M.Taborelli, TS-MME Present specifications: 5 m shape tolerance (…..the best that can be done) Accuracy: quadrant structures

7. 10/2007 M.Taborelli, TS-MME 11.4 GHz Vg1 structure in production (11WDSQVg1) 300 mm

8. 10/2007 M.Taborelli, TS-MME Surface quality Ra=0.02-0.2 Ra= 0.2-0.4 Diamond milling Conventional tools milling 1 mm 0.01 mm quadrant structures

9. 10/2007 M.Taborelli, TS-MME Solvent cleaned Vacuum baked 750C x 1h Effect of thermal treatment quadrant structures Milled surface (carbide tools) 10 µm

10. 10/2007 M.Taborelli, TS-MME Metrology on copper quadrants Measurement: coordinate measuring machine, contact with 0.1N force, accuracy +/-3 µm (at CERN), scan pt. by pt. on the surface ………in parallel with RF low power control quadrant structures Circular-thick HDS-thick

11. 10/2007 M.Taborelli, TS-MME Achieved shape accuracy, milled parts quadrant structures * * *

12. 10/2007 M.Taborelli, TS-MME Alignment: “universal” test piece -Balls and grooves (2 types, magenta and orange) -Elastic averaging shapes (green) -Pins (not shown) -Metrology references are included quadrant structures

13. 10/2007 M.Taborelli, TS-MME RF design of structures Mech. design, fabrication, preparation Test, analysis CTF3 SLACKEK R&D Materials, preparation RF Model The goal is the fabrication of 1 geometry in 4 months and 10 geometries per year; in 2007: 4 received (1 0rdered 2006) + 3 in fabrication Production of structures